Lightweight reusable face shield

ABSTRACT

A face shield assembly including a chassis and a removable protective shield element supported by the chassis is disclosed herein. The chassis includes vertical returns to install accessories, as well as flexible portions to increase retention. The vertical returns mounted to the chassis include mounting points for the shield, and in some embodiments, the shield may slot into the chassis. In one embodiment, the frame is molded as a single, unitary member and in another it is molded from separate pieces which can be constructed into the complete chassis. Various shield embodiments are disclosed, including where the shield extends further toward a user&#39;s ears, but includes a taper to avoid contacting wearers shoulders.

PRIORITY CLAIM

This application claims priority from and the benefit of U.S. Application No. 63/004,378 filed Apr. 2, 2020. The above-referenced application is hereby incorporated by reference in its entirety as if fully set forth herein.

BACKGROUND OF THE PRESENT INVENTION

Prior art face shield products come in two forms, disposable and reusable. Disposable shields are generally flimsy, provide limited protection, and are ill-fitting. Prior art reusable face shields are cumbersome and heavy, and therefore taxing to wear over time, especially for medical professionals who may be required to wear them for hours on end while preforming delicate tasks. The present invention provides a new type of device which is robust, reusable, ergonomic, accommodates a wide variety of users, while also providing superior levels of protection, in a very light weight package.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:

FIG. 1 depicts the chassis of a face shield according to an embodiment of the present invention.

FIG. 2A depicts the underside of the chassis of a face shield according to an embodiment of the present invention.

FIG. 2B depicts the side profile of the chassis of a face shield according to an embodiment of the present invention.

FIG. 2C depicts the underside of a chassis of a face shield, with the shield installed, according to an embodiment of the present invention.

FIGS. 3A-3C depict a face shield according to an embodiment of the present invention.

FIGS. 4A-D depict views of a face shield according to an embodiment of the present invention.

FIG. 5 depicts the front portion of a face shield according to an embodiment of the present invention.

FIG. 6A depicts a front three-quarter view of a face shield according to an embodiment of the present invention.

FIG. 6B depicts a close up of the mounting mechanism of a face shield according to an embodiment of the present invention.

FIG. 6C depicts an exploded view of the components of a face shield according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 depicts the underside of a face shield chassis according to one embodiment 100 of the present invention. As shown, the chassis 101 is generally curved in shape. This shape forms an inner curve 103, which is disposed near the user's head, and an outer curve 102, which forms part of the attachment location for the shield portion. The portion of the chassis 101 between the curves is preferably closed, preventing any splashing from above from entering the user's eyes or face. This closed chassis 101 extends around the user's face toward their ears. In various embodiments, the chassis may include a number of strengthening ribs. For example, ribs may be include at various points along the length of the chassis in order to provide structural rigidity and prevent sagging of the shield while keeping the chassis thin and light. The number of ribs depicted can change depending on the needs of any individual chassis, and the depicted three rib embodiment is not limiting. The strengthening ribs may be located on the underside, as depicted in FIG. 1, or on the top, as necessary. The chassis may be composed of various plastics, medical grade plastics, Fiberglass Reinforced Co-Polymer (FRCP), carbon fiber, titanium, stainless steel, or any other suitably light weight and robust material.

According to a first embodiment, the chassis can include a channel 110 along both of the inner and outer curves. In multi-piece embodiments, the channel accepts a vertical return section, as shown in FIG. 2A. This vertical return 211 section includes mounting points for the shield. The inner vertical return 212 includes mounting points for a forehead pad and head strap. Constructing the shield in this way allows the shield to be shipped flat, and to be manufactured in two-dimensional sheet. The pieces can be assembled in order to create the three-dimensional part.

FIGS. 2A and 2B depict an embodiment of FIG. 1 where the vertical return portions are inserted into the chassis 201. FIG. 2A depicts the returns 211 and 212 inserted into the channels to provide a return for attachment of accessories, such as a shield and comfort/retention mechanisms. Comparing FIG. 1 and FIG. 2A and B, it is clear to see the additions of these vertical portions, or returns, as they are placed in the channels depicted in FIG. 1. These vertical returns may be plastic welded in place, for example, using ABS glue. The vertical returns 211 and 212 provides a location upon which to mount, at the inner curve, a soft material for accepting the user's head. The inner curve can also include mounting points for the adjustable strap near the distal ends of the inner curve vertical return portion. The outer vertical return portion may include a number of holes or fastener posts to removably attach the shield. For example, in on embodiment, the outer vertical return portion may include three holds evenly placed along its length. The shield portion can also include corresponding holes, and may be attached by inserting a push-lock style fastener, or any other type of fastener, through the shield and the outer vertical return portion thereby sandwiching the shield in between the fastener and the vertical return portion.

In various embodiments, the inner edge of the inner vertical return portion 212 can accept a foam piece 207 to soften the connection between the chassis and the wearer. The foam portion 212 is preferably detachable allowing it to be easily replaced. For example, the foam portion may have an adhesive to allow it to removably stick to the return 212. In other embodiments, hook and loop style fasteners may be used on the foam and the corresponding side of the vertical return 212. The size of the foam portion may be changeable depending on the user, but in some embodiments, the foam strip can be 0.75 inches wide and 0.5 inches thick. In additional embodiments, the foam strip can be between 0.25-1.25 inches wide, and between 0.125-1.0 inches thick. Other materials may also be used, such as rubber, or medical grade silicone or plastics.

According to an embodiment of the invention, the horizontal portion of the chassis, as depicted in FIG. 1, can be milled from flat sheet. The vertical components, can also be filled or cut from flat sheet, and are added later, allowing for quick and easy assembly using simpler tools. In alternative embodiments, the vertical portions may be formed in a single piece together with the rest of the chassis.

In various embodiments, the head strap 215 is adjustable in size to accommodate a plurality of users. In one embodiment, the head strap can be formed from a neoprene strap. In alternative embodiments the strap may be composed of any suitable elastic material. Preferably the material is machine washable, and provides some resistance or friction against the user's head in order to more securely hold the apparatus in place. In one illustrative example, the head strap may be cut to have various holes along its length. These holes can accommodate a post located on the chassis or the inner vertical return, for example by stretching the hole over the post to lock the strap into place at the chosen length. The user may shorten the effective length of the strap by choosing to install the strap over the posts on the chassis using holes on the strap that are closer together, or length it by choosing two that are further apart. In at least one embodiment, the head strap is composed of Neoprene, which is laser cut to size and shape. According to one embodiment, the neoprene strap is about 2 mm thick. In some embodiments the neoprene may include a nylon surface on either side, in other embodiments; the neoprene surface may be on both sides or one side. Neoprene provides a secure fit because of its relatively high coefficient of friction against a user's head or hair, and is machine washable, which is preferred in medical fields.

FIG. 2C depicts an embodiment of the present invention with the face shield 220 installed onto pins located into corresponding holes in the outer vertical return. The face shield is preferably made from an optically clear material. For example, the shield may be made out of poly carbonate, polyethylene terephthalate glycol (PETG), impact resistant Lexan, or any other optically clear material. In a preferred embodiment, the face shield is shaped to provide increased protection to the wearer's eyes.

FIG. 3A(1)-(2) depict an additional embodiment, 350. The face shield 355 depicted can be used with the embodiment depicted in FIGS. 2A-C as well as in 3A(1)-(2). The depicted face shield 355 includes wings 356 that extend further back, toward the wearer's ears. This provides increased protection to the wearer. For example, if the wearer turns his or her hear, and the patient coughs, the wearer is still protected from droplets. The face shield is also preferably shaped to allow room for the wearer's shoulders. For example, the embodiment depicted in FIG. 3A(1), the winged portion extending back does not extend all the way to the lower distal end of the shield. Instead there is a taper 357 in the face shield 355. This way, the wearer can bend his or head downward without the shield 355 immediately contacting the wearer's shoulders and thereby limiting the wearer's range of movement, while still providing increased protection.

In various other embodiments, a more traditional face shield may be used, including with embodiment 350, such as the one depicted in FIG. 3B, that do not include the extended wings or the taper. Or, in various embodiments, the extended wings 356 may extend all the way down to the lower end of the shield. The user may select from various shield types as well, as the shields are readily removable and replaceable.

FIG. 3B depicts a complete example of an embodiment of the present invention. The combination of the chassis, the head strap, foam strip, mounting hardware, and shield should preferably weigh less than 8 ounces. Said another way, the complete face shield apparatus preferably weighs less than 8 ounces. The complete face shield can also weigh less than 7 ounces, or 6 ounces, or 5 ounces. The depicted apparatus may be manufactured using CNC, table mills, routers, injection molding, 3D printing or the like, and can be manufactured and shipped flat.

FIGS. 4A-D depict another embodiment 450 of the present invention. Various components, such as, for example, the face shield and head strap, are interchangeable between various embodiments and should not be limited to any particular embodiment. The embodiment 450 includes a chassis 451, the top portion of which depicted in FIG. 4A. The chassis 451 forms the base upon which the head strap 415 and face shield 455 removably attach. The chassis include inner and outer returns. These returns are vertical portions, generally perpendicular to the top and bottom portions of the chassis, and allow for the mounting of various components. The chassis is also closed between the inner and outer returns. This prevents splashing, or water falling, from entering the wearer's eyes or face area from above. The chassis also wraps substantially around the wearers face, again, preventing droplets from entering from above wearers eyes and face along it length including to near the user's ears, as depicted in FIG. 3A. The chassis may be composed of various plastics, FRCP, carbon fiber, titanium, stainless steel, or any other suitably light weight and robust material.

In various embodiments, the vertical returns extend more than the thickness of the material. Said another way, when resting on a flat surface, without a face shield installed, the under portion of the chassis would not contact the surface. Instead, only the inner and outer vertical returns contact the flat surface. Various strengthening ribs 460 may also be included. In various embodiments these ribs may extend up to the height of vertical return away from the top or bottom surface of the chassis.

In preferred embodiments, the chassis extends the face shield far enough away from the wearer's face such that the wearer can comfortably wear glasses without them contacting the face shield, or alternatively, far enough that a wearer can use an N95 mask without it contacting the face shield.

The inner return provides an attachment point for a soft material, such as foam, to accept the user's head. Various other products may be used to comfortably accept the user's forehead. For example, rubbers, foams, or the like. These materials are preferably removable and replaceably attached, for example by adhesive or hook and loop fasteners. The inner return also provides an attachment point for the head strap near the distal ends of the inner return.

FIG. 4D depicts a close up of the embodiment 450. As shown, a pocket 463 is formed near the distal ends of the inner return 462, between the inner return and the chassis 451. This pocket 463 slightly weakens the distal end of the inner return 462. This way, the distal ends of the inner return can bend into the free space formed by the pocket 463. In doing so, the chassis 451 is able to accommodate larger head sizes. When a user with a larger head wears the device, the distal portions of the inner return bend into the free space as necessary, to the point where they may contact the chassis, in order to accommodate various head sizes. Constructing the inner return in this manner also provides slight pressure against the wearer's head, as the inner return attempts to return to its original shape. This slight spring effect increases the stability to the device without introducing any discomfort. An additional benefit of the space between the inner return and the remainder of the chassis at the distal ends is that the free spaces can accommodate the excess portion of the head strap, if any. This keeps the head strap out of the way and increases ergonomics.

In various embodiments, the head strap is adjustable in size to accommodate a plurality of users. In one embodiment, the head strap can be formed from a neoprene strap. In alternative embodiments the strap may be composed of any suitable elastic material. Preferably on that is machine washable, and provides some resistance against the user's head in order to more securely hold the apparatus in place. In one illustrative example, the head strap may be cut to have various holes along its length. These holes can accommodate a post located on the chassis, for example by stretching the hole over the post. The user may shorten the effective length of the strap by choosing to install the strap over the posts on the chassis using holes on the strap that are closer together, or length it by choosing two that are further apart. In at least one embodiment, the head strap is composed of Neoprene, which is laser cut to size and shape. The neoprene is about 2 mm thick. In some embodiments the neoprene may include a nylon surface on either side, in other embodiments; the neoprene surface may be on both sides or one side. Neoprene provides a secure fit because of its relatively high coefficient of friction against a user's head or hair, and is machine washable, which is preferred in medical fields.

In some embodiments of the present invention, the distal end of the inner return includes a strengthening rib along its length (running horizontally). Preferably, this strengthening rib tapers down as it gets closer to the distal end of the return. This provides structural rigidity necessary for a robust device, while also allowing the area of the inner return to bend away to accommodate a user's head, as described above. The taper allows for a controlled bend, for example, more bending at the distal end and less closer to the center of the chassis along its length.

In various embodiments of the present invention, the chassis might include a number of strengthening ribs along its length. The ribs provide structural integrity to prevent unnecessary bending of the main part of the chassis. These strengthening ribs allow the chassis to be manufactured more thinly, and therefore, reduce weight. The ribs may be disposed on the upper or lower portion of the chassis, as necessary. For example, the embodiment depicted in FIG. 4 includes three main ribs running generally perpendicular to the inner and outer returns, as well as a rib near the empty space opposite the distal end of the inner return. These ribs may also be rounded at their edges in order to reduce snagging.

The outer return accepts the face shield, as shown in FIG. 5. In various embodiments, the outer return may include holes, positioned to accept fasteners to allow for removably connecting the face shield, for example, push pins, bolts, screws, or the like. In other embodiments, the outer return may include a number of posts extending away from the face of the return. In additional embodiments, a channel may be formed in the underside of the chassis, near the outer leading edge, and the channel may accept the face shield. According to the depicted embodiment, the face shield may include corresponding holes along its upper edge which allow it to be installed over the posts. In some additional embodiments, an additional decorative or security piece may be placed over the posts, sandwiching the face shield portion between the additional piece and the outer return. Or, alternatively, no additional component may be necessary, as the posts can provide a secure near-interference fit, with the posts. Constructed in this manner, the face shield is preferably readily interchangeable. In various embodiments, the outer return may be slightly inset from the edge of the chassis. This way, any droplets, liquids, or anything else running off of the top of the chassis is less likely to get behind the face mask, since the mask is inset from the leading edge of the chassis. This is depicted in FIG. 5.

The face shield is preferably made from an optically clear material. For example, the shield may be made out of poly carbonate, PETG, impact resistant Lexan, or any other optically clear material. The face shield preferably attaches along the length of the outer return on the chassis. A wide number of attachment points may be used. For example, 2 to 8 points. Alternatively, the face shield may attach along most or all of its length using hook and loop, magnetic, or adhesive means. In a preferred embodiment, the face shield is shaped to provide increased protection to the wearer's eyes and face. For example, as depicted above in FIG. 3A, the face shield includes wings that extend further back, toward the wearer's ears. These wings provide increased protection to the wearer. For example, if the wearer turns his or her hear, and a patient coughs, the wearer is still protected from droplets, because of the wings, despite his or her face being turned. The face shield is also preferably shaped to allow room for the wearer's shoulders. For example, in the embodiment depicted in FIG. 3, the winged portion extending back does not extend all the way to the lower distal end of the shield. This way, the wearer can bend his or head downward without the shield immediately contacting the wearer's shoulders and thereby limiting the wearer's range of movement.

In various other embodiments, a more traditional face shields may be used that do not include the extended wings or the taper. Or, in various embodiments, the extended wings may extend all the way down to the lower end of the shield. The user may select from various shield types as well, as the shields are readily removable and replaceable.

In various embodiments of the present invention, the attachment mechanism for connecting the face shield to the chassis may be configured as depicted in FIG. 6A-6C. This configuration allows for easier manufacturing of the face shield attachment area, namely the posts 671. As depicted, a cutout 670 in the outer edge of the chassis corresponds with each post. These cutouts provide a tooling path such that the tool can create the pin 671 on the chassis, and be removed. To install, the face shield has a number of slots 675 corresponding to the number of posts, these slots are depicted in FIGS. 6B and 6C. These slots 675 accept the post 671 as the face shield is pushed upward into place. A silicon, rubber, or any other suitable material, preferably of a softer durometer than the face shield or the chassis, grommet 676 can be placed over the top of the post. This provides additional security, preventing the face shield from inadvertently sliding past the post and falling off. When the face shield passes over the softer material of the grommet 676, the material gives way, tightly holding the shield in place with a spring-like force. In various embodiments, the upper portion of the shield may also slide into a slot near the leading edge of the chassis, as depicted in FIG. 6B.

The chassis of the presently described embodiment is preferably manufactured via injection molding, 3D printing, computer numerical control (CNC), roto-forming, or the like. A complete apparatus, according to the second preferred embodiment, weighs less than 8 ounces, or less than 6 ounces, or less than 5 ounces. In various embodiments, injection molding techniques may be used to introduce lightening components during manufacture, further decreasing weight.

The various embodiments of the present invention utilize easily replaceable components. That way, should a head strap, face shield, or foam rest become damaged, they can easily be replaced without the near for complete replacement apparatus.

While embodiments of the present invention have been described according to use in a medical scenario, they are not to be so limited. The benefits described above are relevant to any number of fields where a high level of protection and light weight are useful, including, but not limited to, manufacturing, construction, timber, building, art, sports, laboratory environments, and the like.

While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows. 

I claim:
 1. A face shield for protecting a wearers face, comprising: a chassis, comprising: an inner edge, the inner edge configured to be nearer the wearer's head, and comprising a first radius; an outer edge, and the outer edge configured to be further from the wearers head, and comprising a second radius a first slot, the first slot located at the outer edge; a second slot, the second slot located at the inner edge an upper panel, the upper panel connecting the inner edge and the outer edge a removable inner vertical return portion, wherein the inner vertical return portion fits into the second slot; a removable outer vertical return portion, wherein the outer vertical return portion fits into the first slot; a shield, wherein the shield removably attaches to the outer vertical return portion. a head-pad, wherein the head-pad removably attaches to the inner vertical return; and a head-strap, wherein the head strap removably attaches to each distal end of the inner vertical return. 